KR20130004525A - Control system method and apparatus for continuous liquid phase hydroprocessing - Google Patents

Abstract

The present invention is directed to a continuous liquid phase hydroprocessing process, apparatus and process control system without the need to circulate hydrogen gas through a catalyst. By mixing and / or flashing hydrogen and the treated oil in the presence of a solvent or diluent with higher hydrogen solubility relative to the oil feed, it is possible to ensure that all the hydrogen required for the hydrotreating reaction is in solution. The oil / diluent / hydrogen solution can then be fed to a plug flow reactor filled with a catalyst, which is the place where oil and hydrogen react. Since no additional hydrogen is required, large trickle bed reactors can be replaced by much smaller tubular reactors. The amount of hydrogen added to the reactor can be used to control the height of the liquid in the reactor or the pressure in the reactor.

Description

CONTROL SYSTEM METHOD AND APPARATUS FOR CONTINUOUS LIQUID PHASE HYDROPROCESSING

The present invention relates to processes, apparatuses and methods for hydroprocessing processes where the reactants are primarily in the liquid state and no longer need to circulate hydrogen through the catalyst. Related prior art can be found in US Class 208, subclasses 58, 59, 60, 79, 209 and 213. Additional related techniques can be found in US classes 137, subclasses 171, 202 and 392, as well as other classes and subclasses.

The present invention is directed to a continuous liquid phase hydroprocessing process, apparatus and process control system without the need to circulate hydrogen gas through a catalyst. This is accomplished by mixing and / or flashing the hydrogen and the treated oil in the presence of a solvent or diluent with higher hydrogen solubility relative to the oil feed. The present invention also relates to hydrocracking, hydroisomerization and hydrodemetalization.

In hydrotreating, including hydrotreating, hydrofinishing, hydrorefininig, and hydrocracking, the purpose is to saturate or remove sulfur, nitrogen, oxygen, metals, or other contaminants, or to reduce molecular weight. For the purpose of decomposition (decomposition), catalysts are used to react hydrogen with petroleum fractions, distillates, residues or other chemicals. Catalysts with special surface properties are required to provide the activity necessary to carry out the desired reactions.

A conventional treatment system was issued to McConaghy, Jr. on October 6, 1987, initiating a "SHORT RESIDENCE TIME HYDROGEN DONOR DILUENT CRACKING PROCESS." Patent 4,698,147. At McConagi's' 147, hydrogen is fed into the cracking process by mixing the influent with the donor diluent. After the decomposition process, the mixture is separated into product and spent diluent, the spent diluent is regenerated by partial hydrogenation and returned to the inlet flow for the decomposition step. Note that McConagi's' 147 significantly changes the chemical nature of the donor diluent during the process to release the hydrogen needed for decomposition. In addition, McConagi's' 147 process is limited by the upper temperature suppression due to coil caulking, and by the increase in light gas production, which economically limits the maximum decomposition temperature of the process.

U.S. Patent No. 4,857,168, issued to Kubo et al. On August 15, 1989, discloses "METHOD FOR HYDROCRACKING HEAVY FRACTION OIL." Kubo's' 168 uses both a donor diluent and hydrogen gas to supply hydrogen for the catalyst-promoted cracking process. Kubo's' 168 discloses that a moderate supply of heavy fraction oil, donor solvent, hydrogen gas, and catalyst limits the formation of coke on the catalyst and can substantially or completely eliminate coke formation. Kubo's' 168 requires a decomposition reactor containing the catalyst and a separate hydrogenation reactor containing the catalyst. Kubo's' 168 degrees rely on the decomposition of donor diluents to supply hydrogen in the reaction process.

U.S. Patent No. 5,164,074, issued to Houghton on November 17, 1992, shows a "HYDRODESULFURIZATION PRESSURE CONTROL" device for controlling pressure in a combination of hydrodesulfurization and reforming processes. By harmonizing the exhaust control valve for the reforming process in such a way as to ensure that the hydrogen that can be used for desulfurization is maximized before any hydrogen from the reforming process is exhausted through its exhaust valve. The pressure of the hydrogen-rich gas source from the forming process is controlled.

United States Patent No. 4,761,513, issued to Stacy on August 2, 1988, shows "TEMPERATURE CONTROL FOR AROMATIC ALKYLATION PROCESS." Such a temperature control device is a quench system using a methylating agent as the quench medium introduced between sequential reaction zones in the reactor. The enthalpy of the methylating agent is controlled by adjusting the composition ratio of vapor phase and liquid phase methanol, and the temperature is reduced by evaporating the liquid component of the methylating agent.

In conventional hydroprocessing, it is necessary to transfer hydrogen from the vapor phase to a liquid phase in which hydrogen reacts with petroleum molecules on the surface of the catalyst. This is done by circulating very large amounts of hydrogen gas and oil through the catalyst bed. Oil and hydrogen flow through the catalyst bed and hydrogen is absorbed in a thin film of oil distributed over the catalyst. Since the amount of hydrogen required can be as high as 1000 to 5000 SCF / bbl of liquid, the reactor can be operated at very large and harsh conditions, ie hundreds of psi to 5000 psi, and temperatures of about 400 to 900 ° F.

The temperature inside the reactor is difficult to control in conventional systems. The temperature of the oil and hydrogen feed in the reactor can be controlled, but once the feed enters the reactor, there are no control means in the system that can raise or lower the temperature of the oil / hydrogen mixture. Any change in reactor temperature must be carried out using external means. As a result, in conventional systems, when the reactor becomes too hot, cold hydrogen is often injected into the reactor. This cooling method of the reactor is expensive and potentially a safety hazard.

Controlling the reactor temperature is often difficult in conventional systems, but controlling the pressure in the hydrotreatment system is much easier. Using a pressure control system, the pressure in the system is monitored, if the pressure is too high, the pressure is released through the valve, and if the pressure is too low, the pressure in the system is increased. It is not possible to control the pressure on a single hydrotreating reactor using a pressure control system, but this is not very important and instead the pressure is maintained on the entire system rather than on individual reactors.

One of the biggest problems in hydrotreatment is catalytic coking. Caulking occurs when hydrocarbon molecules become too hot in an environment where the amount of hydrogen available is insufficient. The molecule decomposes until it forms coke, a carbonaceous residue. Degradation can occur on the catalyst surface resulting in coke formation and inactivation of the catalyst.

According to the present invention, a process has been developed that does not require circulating hydrogen gas through a catalyst. This is done by mixing and / or flashing the hydrogen and the treated oil in the presence of a “high” solvent or diluent in a constant pressure environment so that the hydrogen is in solution, in the presence of a “high” solvent or diluent relative to the oil feed.

In addition to the reactor conditions, the type and amount of diluent added can be set such that all the hydrogen required for the hydrotreating reaction is in solution. The oil / diluent / hydrogen solution may then be fed to a reactor, for example a plug flow or tubular reactor filled with catalyst, which is the place where oil and hydrogen react. Since no additional hydrogen is required, hydrogen recycle is avoided and the trickle bed operation of the reactor is avoided. Thus, a large trickle bed reactor can be replaced by a much smaller reactor (see FIGS. 1, 2 and 3). Continuous liquid phase reactors can better control the reactor temperature, virtually eliminate catalyst coking, reduce the production of light end hydrocarbons, and make the system safer.

The invention also relates to hydrocracking, hydroisomerization, hydrodemetallization and the like. As described above, the hydrogen gas is mixed and / or flashed with the feedstock and the diluents such as recycled hydrocrackates, isomerates or recycled demetallisates so that the hydrogen is in solution, and then the mixture depletes the catalyst. To pass.

It is an object of the present invention to provide an improved continuous liquid phase hydroprocessing system, process, method and / or apparatus.

It is a further object of the present invention to provide an improved hydrocracking, hydroisomerization, Fischer-Tropsch and / or hydrodemetallization process.

It is another object of the present invention to provide a control method for a reactor in a continuous liquid phase hydrotreatment system, process, method or apparatus.

It is another object of the present invention to provide an improved apparatus for controlling a continuous liquid phase hydrotreatment system, process, method and / or apparatus.

It is another object of the present invention to provide a liquid level control method for a reactor in a continuous liquid phase hydrotreatment system, process, method or apparatus.

It is another object of the present invention to provide a method for controlling the pressure of the vapor phase inside a reactor for a continuous liquid phase hydroprocessing system, process, method or apparatus.

It is another object of the present invention to provide an improved continuous liquid phase hydroprocessing system, process, method and / or apparatus in which liquid can flow into the reactor from the top of the reactor or from the bottom of the reactor.

It is a further object of the present invention to provide an improved continuous liquid phase hydroprocessing system, process, method and / or apparatus in which the design of the system can be a single reactor, multiple reactors and / or multilayer reactors.

It is another object of the present invention to provide a method for reducing light hydrocarbons in a continuous liquid phase hydrotreatment system by venting excess gas at a constant rate directly from the top of the reactor.

In accordance with the present invention, an improved hydrotreatment, hydroreforming, post-hydrotreatment, hydrorefining and / or hydrocracking process reduces or eliminates the need for forced addition of hydrogen into the solution in the reaction vessel, diluents or solvents. By increasing the solubility in hydrogen by adding or selecting a diluent or solvent, a minimum amount of catalyst is used to remove impurities from lubricating oils and waxes at relatively low pressures. For example, the diluent for heavy cuts is diesel fuel and the diluent for light cuts is pentane. Moreover, high solubility can be achieved while using pentane as a diluent. In addition, using the process of the present invention, more than the stoichiometric amount of hydrogen in solution can be achieved. In addition, by using the process of the present invention, the cost of the pressure vessel can be reduced, and the cost can be saved by using the catalyst in small tubes in the reactor. In addition, by using the process of the present invention, it is possible to eliminate the need to use a hydrogen recycle compressor.

The process of the present invention may be used in conventional equipment for hydrotreating, hydroreforming, post-hydrotreating, hydrorefining and / or hydrocracking, but at lower pressures, and / or in advance of recycling solvents, diluents, hydrogen or at least some By carrying out the process using a hydrotreated stock or feed, lower cost equipment, reactors, hydrogen compressors and the like can be used to achieve the same or better results.

1 is a process flow diagram of a diesel hydrogenation reformer.
2 is a process flow diagram of the bottoms hydrogenation reformer.
3 is a process flow diagram of a hydrotreatment system.
4 is a process flow diagram of a multistage reactor system.
5 is a process flowchart of a 1200 BPSD hydroprocessing apparatus.
6 is a diagram of a downflow reactor system in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
7 is a diagram of a downflow reactor system in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
8 is a diagram of an upflow reactor system in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
9 is a diagram of an upflow reactor system in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
10 is a diagram of a downflow two-reactor system in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
11 is a diagram of a downflow two-reactor system in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
12 is a diagram of an upflow two-reactor system in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
13 is a diagram of an upflow two-reactor system in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
FIG. 14 is a diagram of a downflow single reactor system containing two catalyst beds in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
FIG. 15 is a diagram of a downflow single reactor system containing two catalyst beds in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
FIG. 16 is a diagram of an upflow single reactor system containing two catalyst beds in which the amount of liquid in the reactor is controlled by the height of the liquid in the reactor.
FIG. 17 is a diagram of an upflow single reactor system containing two catalyst beds in which the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor.
18 is a diagram of a single bed downflow reactor with a liquid height controller for use in a continuous liquid phase hydroprocessing process.
19 is a diagram of a multi-layer upflow reactor with two pressure controllers for use in a continuous liquid phase hydroprocessing process.

The inventors of the present invention have developed a process that does not require circulating hydrogen gas through a catalyst or having a separate hydrogen phase. This is done by mixing and / or flashing the hydrogen and the treated oil in the presence of a solvent or diluent having a relatively high hydrogen solubility in a constant pressure environment so that the hydrogen is in solution. Excess hydrogen is mixed and / or flashed into the oil / diluent solution so that the maximum volume of oil / diluent solution is utilized for hydrogen. Excess hydrogen that can be dissolved in the oil / diluent solution remains in the vapor phase.

In addition to the reactor conditions, the type and amount of diluent added can be set such that all the hydrogen required for the hydrotreating reaction is in solution. The oil / diluent / hydrogen solution may then be fed to a reactor, for example a plug flow or tubular or other reactor filled with catalyst, which is the place where oil and hydrogen react. Since no additional hydrogen is required, hydrogen recycle is avoided and the trickle bed operation of the reactor is avoided (see FIGS. 1, 2 and 3). Thus, a large trickle bed reactor can be replaced by a much smaller or simpler reactor (see FIG. 18).

In addition to using much smaller or simpler reactors, there is no need to use a hydrogen recycle compressor. Since all the hydrogen required for the reaction can be present in the solution in front of the reactor, there is no need to circulate hydrogen gas in the reactor and no recycle compressor is required. There is no need to use a recirculating compressor, for example using a plug flow or tubular reactor, which greatly reduces the capital cost of the hydroreforming process.

The reactor of the present invention can be modified in design and number to meet the specifications required for the product and a given particular feed. It may be necessary to add additional reactors to achieve the desired product specifications from the specifically contaminated feed. Even when multiple reactors are required, the reactors of the present invention are preferred over conventional reactors because the reactors of the present invention are smaller in size and simpler in design compared to conventional systems, reducing capital costs. In addition to using a multilayer reactor, multiple catalyst beds may be contained within a single reactor vessel. In the case of building a multi-layer reactor (see FIG. 19), capital costs are further reduced by using a single reactor vessel containing multiple catalyst beds. The catalyst layers may contain the same catalyst types or may contain different catalyst types in order to more efficiently achieve product specification goals.

Most of the reactions that occur in hydroprocessing are very exothermic and as a result a significant amount of heat is generated in the reactor. The temperature of the reactor can be controlled using a recycle stream. A controlled volume of reactor effluent may be recycled back to the front of the reactor, if necessary using a reheater, and blended with fresh feed and hydrogen. The recycle stream absorbs heat formed by the reaction of the feed with hydrogen on the catalyst and reduces the temperature rise through the reactor. The reactor temperature can be controlled by controlling the fresh feed temperature and recycle amount if necessary using a preheater. In addition, since the recycle stream contains molecules that have already reacted, it also acts as an inert diluent. The present invention further controls the temperature of the reactor by using a continuous liquid phase reactor, in contrast to conventional trickle bed reactors in which only a thin film of liquid is distributed on the catalyst. An advantage of the continuous liquid phase reactor is that the liquid generally has a higher heat capacity than the gas. The greater the heat capacity of a given molecule, the greater the ability of the molecule to absorb heat from its surroundings while minimizing the temperature itself. The continuous liquid phase reactor acts as a radiator to absorb excess heat from the reactor to balance the overall temperature. When a continuous liquid phase reactor is used, the process becomes even more isothermal, reducing the typical temperature difference between 40 and 60 ° F. (22 to 33 ° C.) between the reactor inlet and reactor outlet to about 10 ° F. (5.5 ° C.). In addition to reducing the temperature difference between the reactor inlet temperature and the reactor outlet temperature, continuous liquid phase reactors also greatly reduce the problem of hot spots in the catalyst bed.

Using the present invention in hydrotreating, coking can be almost eliminated when there is always enough hydrogen in the solution to avoid coking when the decomposition reaction occurs. This can result in much longer catalyst life and lower operating and maintenance costs.

Another problem found in hydroprocessing is the production of light hydrocarbon gases. Such molecules, which are predominantly methane, are undesirable products that, when present in large amounts, must be recovered at an additional cost. These light meal products are increasingly produced as the reaction temperature rises. The problem with the hard meal product is exacerbated by the tendency of the reactor to produce hot spots, which are areas in which the temperature rises significantly above the set temperature of the reactor. To alleviate this problem, conventional hydroprocessing systems use quench boxes located throughout the reactor. The quench box injects cold hydrogen into the reactor to lower the temperature inside the reactor. Hydrogen is not only an expensive choice for cooling the reactor, but it can also pose a safety risk. The design of the quench box and how it controls the introduction of hydrogen into the reactor is very important because one error can lead to loss of control of the entire system. Runaway reactions may also be initiated that may cause an explosion. When using the present invention in hydrotreating, decomposition is often significantly reduced at a rate of 10 times reduction through the use of a continuous liquid phase reactor that also acts as a radiator to form a reactor environment close to isothermal. This nearly isothermal environment eliminates the need for cold hydrogen quench boxes, reduces the capital cost of hydrogen required for the process, and increases the safety of the system.

If a continuous liquid phase reactor is introduced, there is no need to control the temperature of the liquid in the reactor, and thus the radiator, which keeps the system close to isothermal. By controlling the amount of recycle fluid and the temperature of the fresh feed, it is possible to control the temperature of the liquid in the reactor and maintain the radiator without the hydrogen quench box.

Another issue raised with the introduction of continuous liquid phase reactors is the need for a process to control the amount of liquid. This is accomplished by one of two methods. First, by keeping the liquid in the reactor at a certain height, the amount of liquid in the reactor can be controlled (see FIGS. 6, 8, 10, 12, 14 and 16). In this process, there is a specific liquid height range in the reactor that must be maintained. If the height of the liquid becomes too high, it will lower the liquid height by increasing the amount of hydrogen in the oil / diluent / hydrogen mixture entering the reactor. If the height of the liquid is too low, it will reduce the amount of hydrogen in the oil / diluent / hydrogen mixture entering the reactor, allowing more liquid to enter the reactor. In the second control process, the amount of liquid in the reactor can be controlled by maintaining the pressure of the gas inside the reactor (see FIGS. 7, 9, 11, 13, 15 and 17). Excess hydrogen and light hydrocarbon gas in the reactor are maintained at a certain pressure. If the pressure of this gas becomes too high, the optimum pressure will be achieved by reducing the amount of hydrogen in the oil / diluent / hydrogen mixture introduced into the reactor. If the pressure is too low, it will increase the amount of hydrogen in the oil / diluent / hydrogen mixture. In a hydrotreatment system in which multiple reactors or multilayer reactors are used, the amount of liquid in the reactor, or, in the case of a multilayer reactor, the amount of liquid surrounding the catalyst bed is controlled by multiple liquid height or multiple vapor pressures of gas in the top of the reactor. Can be controlled through the sole use of, or the two control methods can be combined in various combinations within the same system.

The present invention differs from conventional techniques in that excess gas can be exhausted directly from the reactor. In conventional hydrogenation reforming, it is not possible to exhaust the gas directly from the reactor because hydrogen gas must be circulated through the reactor. If the gas is vented directly from a conventional reactor, a large amount of hydrogen will be lost or used inefficiently. Because the present invention uses a continuous liquid phase reactor, there is no need to circulate hydrogen through the reactor, so the only gases in the reactor are excess hydrogen and light hydrocarbon gas. Excess gas is directly exhausted from the reactor, minimizing the time required for the system to adapt after a change in exhaust flow rate or the addition of hydrogen to the system or the discharge of hydrogen from the system, thereby enabling more efficient control of the system. do.

FIG. 1 shows a process flow diagram for a diesel hydroreformer represented generally by the number 10. Fresh feedstock 12 is pumped to mixing zone 18 by feed charge pump 14. Fresh feedstock 12 is then mixed with hydrogen 15 and hydromodified feed 16 to form fresh feed mixture 20. The mixture 20 is then separated in the separator 22 to form a mixture 30 separated from the first separator waste 24. The separated mixture 30 is mixed with the catalyst 32 in the reactor 34 to form the reacted mixture 40. The reacted mixture 40 is split into two product streams, recycle stream 42 and continuous stream 50. The recycle flow is pumped by recycle pump 44 to become hydrogenated feed 16, which is mixed with fresh feed 12 and hydrogen 15.

Continuous fluid 50 flows into separator 52, where the second separator waste 54 is removed, resulting in reacted and separated fluid 60. Reacted and separated flow 60 then flows into flasher 62 to form flasher waste 64 and reacted, separated and flashed flow 70. The reacted, separated and flashed flow 70 is then pumped into stripper 72, where stripper waste 74 is removed, thereby forming effluent product 80.

FIG. 2 shows a process flow diagram for the bottoms hydroreformer represented by numeral 100 as a whole. Fresh feed 110 is mixed with solvent 112 in mixing zone 114 and enters mixing zone 124 by mixed solvent-feed fill pump 122. The mixed solvent-feed 120 is then mixed with hydrogen 126 and the hydrogenated feed 128 to form a hydrogen-solvent-feed mixture 130. The hydrogen-solvent-feed mixture 130 is then separated in the first separator 132 to form a mixture 140 separated from the first separator waste 134. The separated mixture 140 is mixed with the catalyst 142 in the reactor 144 to form the reacted mixture 150. The reacted mixture 150 is split into two product flows, recycle flow 152 and continuous flow 160. Recycle flow 152 is pumped by recycle pump 154 to become hydrogenated feed 128, which is mixed with solvent-feed 120 and hydrogen 126.

Continuous fluid 160 flows into second separator 162 where the second separator waste 164 is removed, resulting in reacted and separated fluid 170. Reacted and separated flow 170 then flows into flasher 172 to form flasher waste 174 and reacted, separated and flashed flow 180. Flasher waste 174 is then cooled by condenser 176 to form solvent 112, which is mixed with incoming fresh feed 110.

The reacted, separated and flashed fluid 180 then flows to stripper 182, where stripper waste 184 is removed, thereby forming effluent product 190.

3 shows a process flow diagram for a hydrotreatment apparatus, generally indicated by numeral 200.

The fresh feedstock 202 is mixed with the first diluent 204 in the first mixing zone 206 to form the first diluent-feed 208. The first diluent-feed 208 is then mixed with the second diluent 210 in the second mixing zone 212 to form the second diluent-feed 214. Second diluent-feed 214 is then pumped to third mixing region 218 by diluent-feed charge pump 216.

Hydrogen 220 flows into hydrogen compressor 222 to form compressed hydrogen 224. Compressed hydrogen 224 flows to third mixing region 218.

The second diluent-feed 214 and the compressed hydrogen 224 are mixed in the third mixing zone 218 to form the hydrogen-diluent-feed mixture 226. The hydrogen-diluent-feed mixture 226 is then flowed through the feed-product exchanger 228, which warms the mixture 226 using the third separator discharge 230, thereby providing a first exchanger flow 232. ). The first exchanger flow 232 and the first recycle flow 234 are mixed in the fourth mixing zone 236 to form a first recycle feed 238.

The first recycle feed 238 then flows through a first feed-product exchanger 240 that warms the mixture 238 by using the exchanged first rectifier exchanged effluent 242 so that the second exchanger Form a flow 244. The second exchanger flow 244 and the second recycle flow 246 are mixed in the fifth mixing zone 248, thereby forming a second recycle feed 250.

The second recycle feed 250 is then mixed in the feed-recycle mixer 252 to form the feed-recycle mixture 254. Feed-recycle mixture 254 then flows into reactor inlet separator 256.

Feed-recycle mixture 254 is separated in reactor inlet separator 256 to form reactor inlet separator waste 258 and inlet separated mixture 260. Reactor inlet separator waste 258 is flared or otherwise removed from system 200 of the present invention.

Inlet separated mixture 260 is mixed with catalyst 262 in reactor 264 to form reacted mixture 266. Reacted mixture 266 flows into reactor outlet separator 268.

Reacted mixture 266 is separated in reactor outlet separator 268 to form reactor outlet separator waste 270 and outlet separated mixture 272. Reactor outlet separator waste 270 flows from reactor outlet separator 268 and then flares or otherwise removed from system 200 of the present invention.

The outlet separated mixture 272 flows from the reactor outlet separator 268 and is split into a large recycle flow 274 and a continuous outlet separated mixture 276 in the first split zone 278.

Large recycle flow 274 is pumped to second partition 282 via recycle pump 280. Large recycle flow 274 is divided into first recycle flow 234 and second recycle flow 246 in mixing zone 282 and they are used as described above.

Continuous outlet separated mixture 276 flows out of first partition 278 and flows into effluent heater 284 to become heated effluent flow 286.

The heated effluent flow 286 flows into the first rectifier 288, where it is divided into a first rectifier discharge 290 and a first rectifier flow 292. The first rectifier discharge 290 and the first rectifier flow 292 flow separately into the second exchanger 294, where their temperature difference is reduced.

The exchanger converts the first rectifier exhaust 290 to the first rectifier exchanged exhaust 242, which flows to the first feed-product exchanger 240 as described above. The first feed-product exchanger 240 further cools the first rectifier exchanged effluent 242 to form a first dual cooled effluent 296.

The first double cooled effluent 296 is then cooled by the condenser 298 to become the first condensed effluent 300. The first condensed effluent 300 then flows into the reflux accumulator 302, where it is split into an effluent 304 and a first diluent 204. Effluent 304 exits system 200. The first diluent 204 flows into the first mixing zone 206 and mixes with the first feedstock 202 as described above.

The exchanger converts the first rectifier flow 292 to the first rectifier exchanged flow 306, which flows into the third separator 308. The third separator 308 splits the first rectifier exchanged flow 306 into a third separator discharge 230 and a second rectified flow 310.

The third separator discharge 230 flows to the exchanger 228 as described above. The exchanger 228 cools the third separator discharge 230, thereby forming a second cooled discharge 312.

The second cooled discharge 312 is then cooled by the condenser 314 to become the third condensed discharge 316. Third condensed effluent 316 then flows into reflux accumulator 318, where it is split into reflux accumulator exhaust 320 and second diluent 210. Reflux accumulator exhaust 320 exits system 200. The second diluent 210 flows into the second mixing zone 212 and rejoins the system 200 as described above.

The second rectified flow 310 flows into the second rectifier 322 where it is divided into a third rectifier discharge 324 and a first end flow 326. The first end flow 326 then flows out of the system 200 for use or further processing. The third rectifier discharge 324 flows into the condenser 328 where it is cooled to become the third condensed discharge 330.

The third condensed effluent 330 flows from the condenser 328 into the fourth separator 332. The fourth separator 332 divides the third condensed effluent 330 into a fourth separator effluent 334 and a second end flow 336. The fourth separator discharge 334 exits the system 200. The second end flow 336 then flows out of the system 200 for use or further processing.

4 shows a process flow diagram for a 1200 BPSD hydrotreatment apparatus, indicated generally by the numeral 400.

Fresh feedstock 401 is monitored at first monitoring point 402 for allowable inflow parameters of about 260 ° F. (127 ° C.) at 20 psi (138 kPa) and 1200 BBL / D. Fresh feed 401 is then mixed with diluent 404 in first mixing zone 406 to form mixed diluent-feed 408. The mixed diluent-feed 408 is then pumped by the diluent-feed fill pump 410 through the first monitoring orifice 412 and the first valve 414 to the second mixing region 416.

Hydrogen 420 is introduced into hydrogen compressor 422 at variables of 100 ° F. (37.8 ° C.), 500 psi (3447 kPa) and 40,000 SCF / HR (1133 m 3 / hr) to form compressed hydrogen 424. Hydrogen compressor 422 compresses hydrogen 420 to 1500 psi (2896 to 10,342 kPa). Compressed hydrogen 424 flows through a second monitoring point 426 that monitors acceptable inflow parameters. Compressed hydrogen 424 flows to second mixing region 416 through second monitoring orifice 428 and second valve 430.

The first monitoring orifice 412, the first valve 414 and the feed forward indicator and controller (FFIC) 434 are directed to the second mixing zone 416 of the mixed diluent-feed 408. And a feed indicator controller (FIC) 432 to control the inflow of water. Similarly, a second monitoring orifice 428, a second valve 430, and an FIC 432 are connected to the FFIC 434 that controls the inflow of compressed hydrogen 424 into the second mixing region 416. . Mixed diluent-feed 408 and compressed hydrogen 424 are mixed in second mixing zone 416 to form hydrogen-diluent-feed mixture 440. The mixture variable is about 1500 psi (10,342 kPa) and 2516 BBL / D monitored at the fourth monitoring point 442. The hydrogen-diluent-feed mixture 440 is then flowed through a feed-product exchanger 444 which warms the hydrogen-diluent-feed mixture 440 using the rectified product 610, thereby providing an exchanger oil. The animal 446 is formed. Feed-product exchanger 444 operates at about 2.584 MMBTU / HR (756 kW).

The exchanger flow 446 is monitored at the fifth monitoring point 448 so that information about the variables of the exchanger flow 446 is collected.

Exchanger flow 446 is then introduced into reactor preheater 450 capable of heating exchanger flow 446 at 5.0 MMBTU / HR (1456 kW) to form preheated fluid 452. Preheated flow 452 is monitored by TIC 456 at sixth monitoring point 454.

Fuel gas 458 flows through third valve 460 and is monitored by a pressure indicator and controller (PIC) 462 that fuels reactor preheater 450. PIC 462 is coupled to third valve 460 and temperature indicator and controller (TIC) 456.

Preheated fluid 452 is mixed with recycle fluid 464 in third mixing zone 466 to form preheated recycle fluid 468. Preheated recycle flow 468 is monitored at seventh monitoring point 470. Preheated recycle flow 468 is then mixed in feed-recycle mixer 472 to form feed-recycle mixture 474. Feed-recycle mixture 474 then flows into reactor inlet separator 476. Reactor inlet separator 476 has a variable of 60 "I.D. x 10'0" S / S (1.52 m x 3.05 m).

Feed-recycle mixture 474 is separated in reactor inlet separator 476 to form reactor inlet separator waste 478 and inlet separated mixture 480. Reactor inlet separator waste 478 flows from reactor inlet separator 476 through a third monitoring orifice 482 connected to FI 484. The reactor inlet separator waste 478 then flows through the fourth valve 486 past the eighth monitoring point 488 and is then flared or otherwise removed from the system 400 of the present invention.

Liquid indicator and controller (LIC) 490 are connected to both fourth valve 486 and reactor inlet separator 476.

Inlet separated mixture 480 flows from reactor inlet separator 476 with variables of about 590 ° F. (310 ° C.) and 1500 psi (10,342 kPa) monitored at ninth monitoring point 500.

Inlet separated mixture 480 is mixed with catalyst 502 in reactor 504 to form reacted mixture 506. The reacted mixture 506 is monitored by the TIC 508 at the tenth monitoring point 510 for process control. Reacted mixture 506 has variables of 605 ° F. (232 ° C.) and 1450 psi (9997 kPa) as it flows into reactor outlet separator 512.

Reacted mixture 506 is separated in reactor outlet separator 512 to form reactor outlet separator waste 514 and outlet separated mixture 516. Reactor outlet separator waste 514 flows from reactor outlet separator 512 through monitor 515 for PIC 518. The reactor outlet separator waste 514 then flows past the eleventh monitoring point 520 through the fifth valve 522 and is then flared or otherwise removed from the system 400 of the present invention.

Reactor outlet separator 512 is connected to controller LIC 524. Reactor outlet separator 512 has a variable of 60 "I.D. x 10'0" S / S (1.52 m x 3.05 m).

The outlet separated mixture 516 flows from the reactor outlet separator 512 and is split into a continuous outlet separated mixture 526 with a recycle flow 464 in the first splitting zone 528.

The recycle flow 464 is pumped through the recycle pump 530 past the twelfth monitoring point 532 to the fourth monitoring orifice 534. The fourth monitoring orifice 534 is connected to the FIC 536, which is connected to the TIC 508. FIC 536 controls sixth valve 538. After the recycle flow 464 flows out of the fourth monitoring orifice 534, the flow 464 flows in the third mixing zone 466 through the sixth valve 538, where it is as described above. It is mixed with the preheated fluid 452.

The outlet separated mixture 526 flows out of the first partition 528 and flows through a seventh valve 540 controlled by the LIC 524. The outlet separated mixture 526 then flows through the thirteenth monitoring point 542 to the effluent heater 544.

The outlet separated mixture 526 then enters the heated effluent stream 546 by entering an effluent heater 544 capable of heating the outlet separated mixture 526 at 3.0 MMBTU / HR (879 kW). Form. The heated effluent flow 546 is monitored by the TIC 548 at the fourteenth monitoring point 550. Fuel gas 552 flows through the eighth valve 554 and is monitored by the PIC 556 which fuels the effluent heater 544. PIC 556 is connected to an eighth valve 554 and a TIC 548.

The heated effluent flow 546 flows from the fourteenth monitoring point 550 into the rectifier 552. Rectifier 552 is connected to LIC 554. Steam 556 flows into rectifier 552 through twentieth monitoring point 558. Return diluent flow 560 also flows into rectifier 552. Rectifier 552 has a variable 42 "I.D. x 54'0" S / S (1.07 m x 16.46 m).

Rectifier diluent 562 flows from rectifier 552 past the monitor for TIC 564 and beyond the fifteenth monitoring point 566. Rectifier diluent 562 then flows through rectifier overhead condenser 568. Rectifier overhead condenser 568 uses flow CWS / R 570 to modify rectifier diluent 562 to form condensed diluent 572. Rectifier overhead condenser 568 has a variable of 5.56 MMBTU / HR (1629 kW).

Condensed diluent 572 then flows into rectifier reflux accumulator 574. Rectifier reflux accumulator 574 has a variable 42 "I.D. x 10'0" S / S (1.07 m x 3.05 m). Rectifier reflux accumulator 547 is monitored by LIC 592. Rectifier reflux accumulator 574 divides the condensed diluent 572 into three streams, effluent stream 576, gas stream 580, and diluent stream 590.

Outlet stream 576 flows out of rectifier reflux accumulator 574 past monitor 578 and exits system 400.

Gas stream 580 flows from rectifier reflux accumulator 574 through eighteenth monitoring point 594 through pump 596 to form pumped diluent stream 598. The pumped diluent stream 598 is then split into diluent 404 and return diluent flow 560 in second dividing zone 600. Diluent 404 flows from second partition 600 through tenth valve 602 and third monitoring point 604. Diluent 404 then flows from third monitoring point 604 to first mixing zone 406 where it is mixed with fresh feedstock 401 as described above.

Return diluent flow 560 flows from the second partitioned area 600 through the eleventh monitoring point 606 through the eleventh valve 608 to the rectifier 552. Eleventh valve 608 is connected to TIC 564.

Rectified product 610 flows from rectifier 552 past twenty-first monitoring point 612 into exchanger 444 to form exchanged and rectified product 614. The exchanged and rectified product 614 then flows through the product pump 616 past the twenty-second monitoring point 615. The exchanged and rectified product 614 flows from the pump 616 through the fifth monitoring orifice 618. Sixth monitoring orifice 618 is connected with FI 620. The exchanged and rectified product then flows from the sixth monitoring orifice 618 to the twelfth valve 622. The twelfth valve 622 is connected to the LIC 554. The exchanged and rectified product 614 then flows from the twelfth valve 622 through the twenty-third monitoring point 624 into the product cooler 626 where it is cooled to form the final product 632. Product cooler 626 uses CWS / R 628. The product cooler has a variable of 0.640 MMBTU / HR (187.5 kW). The final product 632 flows from the cooler 626 past the twenty-fourth monitoring point 630 and exits the system 400.

5 shows a process flow diagram for a multistage hydrogenation reformer, represented generally by the number 700. Feed 710 is mixed with hydrogen 712 and first recycle stream 714 in zone 716 to form mixed feed-hydrogen-recycle stream 720. Mixed feed-hydrogen-recycle stream 720 flows into first reactor 724 where it reacts to form first reactor effluent stream 730. The first reactor effluent flow 730 is split in zone 732 to form a first recycle stream 714 and a first continuous reactor flow 740. First continuous reactor flow 740 flows into stripper 742, where stripper waste 744 such as H ₂ S, NH ₃ and H ₂ O is removed to form stripped flow 750. .

Stripped flow 750 is then mixed with additional hydrogen 752 and second recycle stream 754 in region 756 to form mixed stripped-hydrogen-recycle stream 760. Mixed stripped-hydrogen-recycle stream 760 flows into saturation reactor 764 where it reacts to form second reactor effluent flow 770. The second reactor effluent stream 770 is split in zone 772 to form a second recycle stream 754 and a product effluent 780.

FIG. 6 is a diagram of a downflow reactor system, represented generally by the number 800, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feedstock 802 flows through first orifice 804 into first partition 810. The recycled and reacted product 956 flows into the second orifice 806, and the mixed recycled and reacted product and feed 812 flow out of the first partition 810 through the third orifice 808. do. The mixed recycled and reacted product and feed 812 then enters the mixer 820 through the first mixer inlet 824, where it enters hydrogen (2) into the mixer 820 through the second mixer inlet 828. 832). The amount of hydrogen 832 is controlled by the hydrogen valve 830. Recycled and reacted product / feed / hydrogen 822 exits mixer 820 via mixer outlet 826 and flows into reactor 840 through reactor inlet 842. Within reactor 840, recycled and reacted product / feed / hydrogen 822 reacts while flowing through catalyst bed 860. As the recycled and reacted product / feed / hydrogen 822 reacts, hydrogen gas and light hydrocarbon gas 845 may be released from solution and accumulate at the top of reactor 840. Gas 845 is removed from reactor 840 via reactor orifice 847. The rate at which gas 845 is removed from reactor 840 via orifice 847 is controlled by exhaust valve 870.

The height of the liquid recycled and reacted product / feed / hydrogen 822 is monitored by a height controller 850 located above the catalyst bed 860. If the height of the liquid recycled and reacted product / feed / hydrogen 822 is higher than the desired liquid height, the height controller 850 increases the amount of hydrogen entering the mixer 820 to the hydrogen valve 830. Will signal. If the height of the liquid recycled and reacted product / feed / hydrogen 822 is lower than the desired liquid height, the height controller 850 reduces the amount of hydrogen entering the mixer 820 to the hydrogen valve 830. Will signal.

Reacted liquid 846 flows out of reactor 840 via reactor outlet 844. The reacted liquid 846 flows through the fourth orifice 942 into the second divided region 940, where it is the second divided region 940 through the fifth orifice 944, which is two fluids. Split and reacted product 952 exiting from and through recycled and reacted product 956 exiting second partition 940 through sixth orifice 946. The recycled and reacted product 956 is pumped through the recycle pump 960 and then mixed with fresh feed 802 in the first partition 810.

FIG. 7 is a diagram of a downflow reactor system, represented generally by the numeral 1000, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feed 1002 flows through first orifice 1004 into first partition 1010. Recycled and reacted product 1156 flows into second orifice 1006 and mixed recycled and reacted product and feed 1012 flows out of first partition 1010 through third orifice 1008 do. The mixed recycled and reacted product and feed 1012 then enters the mixer 1020 through the first mixer inlet 1024, where it enters the hydrogen (10) into the mixer 1020 through the second mixer inlet 1028. 1032). The amount of hydrogen 1032 is controlled by the hydrogen valve 1030. Recycled and reacted product / feed / hydrogen 1022 flows out of mixer 1020 through mixer outlet 1026 and flows into reactor 1040 through reactor inlet 1042. Within reactor 1040, the recycled and reacted product / feed / hydrogen 1022 reacts while flowing through catalyst bed 1060. As the recycled and reacted product / feed / hydrogen 1022 reacts, hydrogen gas and light hydrocarbon gas 1045 may be released from solution and accumulated at the top of reactor 1040. Gas 1045 is removed from reactor 1040 through reactor orifice 1047. The rate at which gas 1045 is removed from reactor 1040 through orifice 1047 is controlled by exhaust valve 1070.

The pressure of excess hydrogen and light hydrocarbon gas 1045 is monitored by pressure controller 1050 located above catalyst bed 1060. If the pressure of the gas 1045 is higher than the desired gas pressure, the pressure controller 1050 will signal the hydrogen valve 1030 to reduce the amount of hydrogen entering the mixer 1020. If the pressure of the gas 1045 is lower than the desired gas pressure, the pressure controller 1050 will signal the hydrogen valve 1030 to increase the amount of hydrogen entering the mixer 1020.

Reacted product 1046 exits reactor 1040 through reactor outlet 1044. Reacted product 1046 flows through second orifice 1142 into second partition 1140, where it is two flows, second partition 1140 through fifth orifice 1144. Split and reacted product 1152 exiting from and through recycled and reacted product 1156 exiting second partition 1140 through sixth orifice 1146. The recycled and reacted product 1156 is pumped through the recycle pump 1160 and then mixed with fresh feed 1002 in the first partition 1010.

FIG. 8 is a diagram of an upward flow reactor system, represented generally by the number 1200, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feed 1202 flows through first orifice 1204 into first partition 1210. Recycled and reacted product 1356 flows into second orifice 1206 and mixed recycled and reacted product and feed 1212 flows out of first partition 1210 through third orifice 1208. do. The mixed recycled and reacted product and feed 1212 then enters the mixer 1220 through the first mixer inlet 1224, where it enters the hydrogen (12) into the mixer 1220 through the second mixer inlet 1228. 1232). The amount of hydrogen 1232 is controlled by the hydrogen valve 1230. Recirculated and reacted product / feed / hydrogen 1222 flows out of mixer 1220 through mixer outlet 1226 and flows into reactor 1240 through reactor inlet 1242. Within the reactor 1240, the recycled and reacted product / feed / hydrogen 1222 reacts while flowing through the catalyst bed 1260. As the recycled and reacted product / feed / hydrogen 1222 reacts, hydrogen gas and light hydrocarbon gas 1245 may be released from solution and accumulated at the top of reactor 1240. Gas 1245 is removed from reactor 1240 through reactor orifice 1247. The rate at which gas 1245 is removed from reactor 1240 through orifice 1247 is controlled by exhaust valve 1270.

The height of the liquid recycled and reacted product / feed / hydrogen 1222 is monitored by a height controller 1250 located above the catalyst bed 1260. If the height of the liquid recycled and reacted product / feed / hydrogen 1222 is higher than the desired liquid height, the height controller 1250 increases the amount of hydrogen entering the mixer 1220 to the hydrogen valve 1230. Will signal. If the height of the liquid recycled and reacted product / feed / hydrogen 1222 is lower than the desired liquid height, the height controller 1250 reduces the amount of hydrogen entering the mixer 1220 to the hydrogen valve 1230. Will signal.

Reacted product 1246 exits reactor 1240 through reactor outlet 1244. Reacted product 1246 flows through second orifice 1242 into second splitting region 1240, where it is two flows, second splitting region 1340 through fifth orifice 1344. Split and reacted product 1252 and the recycled and reacted product 1356 exiting the second partition 1340 through the sixth orifice 1346 are discharged from. The recycled and reacted product 1356 is pumped through the recycle pump 1360 and then mixed with fresh feed 1202 in the first partition 1210.

FIG. 9 is a diagram of an upward flow reactor system, represented generally by the numeral 1400, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feedstock 1402 flows through first orifice 1404 into first partition 1410. Recycled and reacted product 1556 flows into second orifice 1406 and mixed recycled and reacted product and feed 1412 flows out of first partition 1410 through third orifice 1408. do. The mixed recycled and reacted product and feed 1412 then enters the mixer 1420 through the first mixer inlet 1424, where it enters the hydrogen (1) into the mixer 1420 through the second mixer inlet 1428. 1432). The amount of hydrogen 1432 is controlled by the hydrogen valve 1430. Recycled and reacted product / feed / hydrogen 1422 exits mixer 1420 through mixer outlet 1426 and flows into reactor 1440 through reactor inlet 1442. Within the reactor 1440, the recycled and reacted product / feed / hydrogen 1422 reacts while flowing through the catalyst bed 1460. As the recycled and reacted product / feed / hydrogen 1422 reacts, hydrogen gas and light hydrocarbon gas 1445 may be released from solution and accumulate at the top of reactor 1440. Gas 1445 is removed from reactor 1440 through reactor orifice 1447. The rate at which gas 1445 is removed from reactor 1440 through orifice 1447 is controlled by exhaust valve 1470.

The pressure of excess hydrogen and light hydrocarbon gas 1445 is monitored by a pressure controller 1450 located above the catalyst bed 1460. If the pressure of gas 1445 is higher than the desired gas pressure, pressure controller 1450 will signal hydrogen valve 1430 to reduce the amount of hydrogen entering the mixer 1420. If the pressure of gas 1445 is lower than the desired gas pressure, pressure controller 1450 will signal hydrogen valve 1430 to increase the amount of hydrogen entering the mixer 1420.

Reacted product 1446 exits reactor 1440 via reactor outlet 1444. Reacted product 1446 flows through second orifice 1542 into second partition 1540, where it is two flows, second split zone 1540 through fifth orifice 1544. The split and reacted product 1552 and the sixth orifice 1546 are discharged from the recycled and reacted product 1556, which exits from the second partition 1540. The recycled and reacted product 1556 is pumped through the recycle pump 1560 and then mixed with fresh feed 1402 in the first partition 1410.

10 is a diagram of a downflow two-reactor system, represented generally by the numeral 1800, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feed 1802 flows through first orifice 1804 into first partition 1810. Recycled and reacted product 1956 flows into second orifice 1806, and mixed recycled and reacted product and feed 1812 flows out of first partition 1810 through third orifice 1808. do. The mixed recycled and reacted product and feed 1812 then enters the first mixer 1820 through the first mixer inlet 1824, where it is through the second mixer inlet 1828 and the first mixer 1820. Mixed with hydrogen (1832). The amount of hydrogen 1832 is controlled by the first hydrogen valve 1830. Recycled and reacted product / feed / hydrogen 1822 flows out of the first mixer 1820 via the first mixer outlet 1826 and flows into the first reactor 1840 through the first reactor inlet 1842. . Within the first reactor 1840, recycled and reacted product / feed / hydrogen 1822 reacts while flowing through the first catalyst bed 1860. As the recycled and reacted product / feed / hydrogen 1822 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 1845 may be released from the solution and accumulate at the top of the first reactor 1840. The first catalyst bed gas 1845 is removed from the first reactor 1840 via the first reactor orifice 1847. The rate at which the first catalyst bed gas 1845 is removed from the first reactor 1840 through the first reactor orifice 1847 is controlled by the first exhaust valve 1870.

The height of the liquid recycled and reacted product / feed / hydrogen 1822 is monitored in a first height controller 1850 located above the first catalyst bed 1860. If the height of the liquid recycled and reacted product / feed / hydrogen 1822 is higher than the desired liquid height, the first height controller 1850 enters the first hydrogen valve 1830 into the first mixer 1820. It will send a signal to increase the amount of hydrogen. If the height of the liquid recycled and reacted product / feed / hydrogen 1822 is lower than the desired liquid height, the first height controller 1850 enters the first hydrogen valve 1830 into the first mixer 1820. It will send a signal to reduce the amount of hydrogen.

The first catalyst bed product 1846 flows out of the first reactor 1840 through the first reactor outlet 1844. The first catalyst bed product 1846 flows through the third mixer inlet 1884 into the second mixer 1880, where it enters the second mixer 1880 through the fourth mixer inlet 1888 and enters hydrogen 1892. Mixed with The amount of hydrogen 1892 is controlled by the second hydrogen valve 1890. The first catalyst bed product / hydrogen 1882 flows out of the second mixer 1880 through the second mixer outlet 1886 and flows into the second reactor 1900 through the second reactor inlet 1902. Within the second reactor 1900, the first catalyst bed product / hydrogen 1882 flows through the second catalyst bed 1920, where it reacts. As the first product / hydrogen 1882 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 1905 may be released from the solution and accumulate at the top of the second reactor 1900. The second catalyst bed gas 1905 is removed from the second reactor 1900 through the second reactor orifice 1907. The rate at which the second catalyst bed gas 1905 is removed from the second reactor 1900 through the second reactor orifice 1907 is controlled by the second exhaust valve 1930.

The height of the first catalyst bed product / hydrogen 1882 is monitored in a second height controller 1910 located above the second catalyst bed 1920. If the height of the first catalyst bed product / hydrogen 1882 is higher than the desired liquid height, the second height controller 1910 increases the amount of hydrogen entering the second mixer 1880 to the second hydrogen valve 1890. Will send a signal. When the height of the first catalyst bed product / hydrogen 1882 is lower than the desired liquid height, the second height controller 1910 reduces the amount of hydrogen flowing into the second mixer 1880 to the second hydrogen valve 1890. Will send a signal.

Reacted product 1906 exits second reactor 1900 through second reactor outlet 1904. The reacted product 1906 flows through the fourth orifice 1942 into the second partitioned zone 1940, where it is two flows, the second partitioned zone 1940 through the fifth orifice 1944. Split and reacted product (1952) exiting from and recycled and reacted product (1956) exiting from the second partition (1940) through the sixth orifice (1946). The recycled and reacted product 1956 is pumped through the recycle pump 1960 and then mixed with fresh feed 1802 in the first partition 1810.

FIG. 11 is a diagram of a downflow two-reactor system, represented generally by the numeral 2000, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feedstock 2002 flows through first orifice 2004 into first partition 2010. Recycled and reacted product 2156 flows into second orifice 2006 and mixed recycled and reacted product and feed 2012 exits first partition 2010 through third orifice 2008 do. The mixed recycled and reacted product and feed 2012 then enter the first mixer 2020 through the first mixer inlet 2024, where it is the first mixer 2020 through the second mixer inlet 2028. Mixed with hydrogen 2032 entered. The amount of hydrogen 2032 is controlled by the first hydrogen valve 2030. The recycled and reacted product / feed / hydrogen 2022 flows out of the first mixer 2020 through the first mixer outlet 2026 and flows into the first reactor 2040 through the first reactor inlet 2042. . Within the first reactor 2040, the recycled and reacted product / feed / hydrogen 2022 reacts as it flows through the first catalyst bed 2060. As the recycled and reacted product / feed / hydrogen 2022 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 2045 may be released from the solution and accumulate at the top of the first reactor 2040. The first catalyst bed gas 2045 is removed from the first reactor 2040 through the first reactor orifice 2047. The rate at which gas 2045 is removed from first reactor 2040 through first reactor orifice 2047 is controlled by first exhaust valve 2070.

The pressure of excess first catalyst bed hydrogen and light hydrocarbon gas 2045 is monitored by a first pressure controller 2050 located above the first catalyst bed 2060. If the pressure of the first catalyst bed gas 2045 is higher than the desired gas pressure, the first pressure controller 2050 tells the first hydrogen valve 2030 to reduce the amount of hydrogen entering the first mixer 2020. Will send a signal. If the pressure of the first catalyst bed gas 2045 is lower than the desired gas pressure, the first pressure controller 2050 tells the first hydrogen valve 2030 to increase the amount of hydrogen entering the first mixer 2020. Will send a signal.

The first catalyst bed product 2046 exits the first reactor 2040 through the first reactor outlet 2044. The first catalyst bed product 2046 flows through the third mixer inlet 2084 into the second mixer 2080, where it enters the second mixer 2080 through the fourth mixer inlet 2088 and enters the hydrogen 2092. Mixed with The amount of hydrogen 2092 is controlled by the second hydrogen valve 2090. The first catalyst bed product / hydrogen 2082 flows out of the second mixer 2080 through the second mixer outlet 2086 and flows into the second reactor 2100 through the second reactor inlet 2102. Within the second reactor 2100, the first catalyst bed product / hydrogen 2182 reacts while flowing through the second catalyst bed 2120. As the first catalyst bed product / hydrogen 2208 reacts, the second catalyst bed hydrogen gas and light hydrocarbon gas 2105 may be released from the solution and accumulate at the top of the second reactor 2100. The second catalyst bed gas 2105 is removed from the second reactor 2100 through the second reactor orifice 2107. The rate at which the second catalyst bed gas 2105 is removed from the second reactor 2100 through the second reactor orifice 2107 is controlled by the second exhaust valve 2130.

The pressure of the excess second catalyst bed hydrogen and light hydrocarbon gas 2105 is monitored in a second pressure controller 2110 located above the second catalyst bed 2120. If the pressure of the second catalyst bed gas 2105 is higher than the desired gas pressure, the second pressure controller 2110 may cause the second hydrogen valve 2090 to reduce the amount of hydrogen flowing into the first mixer 2080. Will send a signal. When the pressure of the second catalyst bed gas 2105 is lower than the desired gas pressure, the second pressure controller 2110 tells the second hydrogen valve 2090 to increase the amount of hydrogen flowing into the second mixer 2080. Will send a signal.

Reacted product 2106 exits second reactor 2100 through second reactor outlet 2104. Reacted product 2106 flows through second orifice 2142 into second partition 2140, where it is two flows, second partition 2140 through fifth orifice 2144. Split and reacted product 2152 and recycled and reacted product 2156 exiting second partition 2140 through sixth orifice 2146 are discharged from. The recycled and reacted product 2156 is pumped through the recycle pump 2160 and then mixed with fresh feed 2002 in the first partition 2010.

FIG. 12 is a diagram of an upflow two-reactor system, represented generally by the numeral 2200, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feed 2202 flows through first orifice 2204 into first partition 2210. Recycled and reacted product 2356 flows into second orifice 2206, and mixed recycled and reacted product and feed 2212 flows out of first partition 2222 through third orifice 2208. do. The mixed recycled and reacted product and feed 2212 then enters the first mixer 2220 through the first mixer inlet 2224, where it is through the first mixer inlet 2228 and the first mixer 2220. Mixed with hydrogen (2232). The amount of hydrogen 2232 is controlled by the first hydrogen valve 2230. Recycled and reacted product / feed / hydrogen 2222 flows out of first mixer 2220 through first mixer outlet 2226 and flows into first reactor 2240 through first reactor inlet 2242. . Within the first reactor 2240, the recycled and reacted product / feed / hydrogen 2222 reacts while flowing through the first catalyst bed 2260. As the recycled and reacted product / feed / hydrogen 2222 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 2245 may be released from solution and accumulate at the top of reactor 2240. First catalyst bed gas 2245 is removed from first reactor 2240 through first reactor orifice 2247. The rate at which first catalyst bed gas 2245 is removed from first reactor 2240 through first reactor orifice 2247 is controlled by first exhaust valve 2270.

The height of the liquid recycled and reacted product / feed / hydrogen 2222 is monitored by a first height controller 2250 located above the first catalyst bed 2260. If the height of the liquid recycled and reacted product / feed / hydrogen 2222 is higher than the desired liquid height, first height controller 2250 enters first hydrogen valve 2230 into first mixer 2220. It will send a signal to increase the amount of hydrogen. If the height of the liquid recycled and reacted product / feed / hydrogen 2222 is lower than the desired liquid height, first height controller 2250 enters first hydrogen valve 2230 into first mixer 2220. It will send a signal to reduce the amount of hydrogen.

The first catalyst bed product 2246 exits the first reactor 2240 through the first reactor outlet 2244. The first catalyst bed product 2246 flows through the third mixer inlet 2284 into the second mixer 2280, where it enters the second mixer 2280 through the fourth mixer inlet 2288 and enters the hydrogen 2292. Mixed with The amount of hydrogen 2292 is controlled by the second hydrogen valve 2290. The first catalyst bed product / hydrogen 2228 flows out of second mixer 2280 through second mixer outlet 2286 and flows into second reactor 2300 through second reactor inlet 2302. Within the second reactor 2300, the first catalyst bed product / hydrogen 2228 reacts while flowing through the second catalyst bed 2320. As the first catalyst layer product / hydrogen 2228 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 2305 may be released from the solution and accumulate at the top of the second reactor 2300. The second catalyst bed gas 2305 is removed from the second reactor 2300 through the second reactor orifice 2307. The rate at which the second catalyst bed gas 2305 is removed from the second reactor 2300 through the second reactor orifice 2307 is controlled by the second exhaust valve 2330.

The height of the first catalyst bed product / hydrogen 2228 is monitored by a second height controller 2310 located above the second catalyst bed 2320. If the height of the first catalyst bed / hydrogen 2228 is higher than the desired liquid height, then the second height controller 2310 increases the amount of hydrogen flowing into the second mixer 2280 to the second hydrogen valve 2290. Will signal. If the height of the first catalyst bed product / hydrogen 2228 is lower than the desired liquid height, the second height controller 2310 increases the amount of hydrogen flowing into the second mixer 2280 to the second hydrogen valve 2290. Will send a signal.

Reacted product 2306 exits second reactor 2300 through second reactor outlet 2304. Reacted product 2306 flows into second partition 2340 through fourth orifice 2342, where it is two flows, second partition 2340 through fifth orifice 2344. And the recycled and reacted product 2356 which exits from the second partition 2340 via the split and reacted product 2352 and the sixth orifice 2346 which flow out from. The recycled and reacted product 2356 is pumped through the recycle pump 2360 and then mixed with fresh feed 2302 in the first partition 2310.

FIG. 13 is a diagram of an upflow two-reactor system, represented generally by the numeral 2400, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feed 2402 flows through first orifice 2404 into first partition 2410. Recycled and reacted product 2556 flows into second orifice 2406, and mixed recycled and reacted product and feed 2412 flow out of first partition 2410 through third orifice 2408. do. The mixed recycled and reacted product and feed 2412 then enter the first mixer 2420 through the first mixer inlet 2424, where it is through the second mixer inlet 2428 and the first mixer 2420. Mixed with hydrogen 2432 entered. The amount of hydrogen 2432 is controlled by the first hydrogen valve 2430. Recycled and reacted product / feed / hydrogen 2422 flows out of the first mixer 2420 through the first mixer outlet 2426 and flows into the first reactor 2440 through the first reactor inlet 2442. . Within the first reactor 2440, the recycled and reacted product / feed / hydrogen 2422 reacts while flowing through the first catalyst bed 2460. As the recycled and reacted product / feed / hydrogen 2422 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 2445 may be released from the solution and accumulate at the top of the first reactor 2440. The first catalyst bed gas 2445 is removed from the first reactor 2440 through the first reactor orifice 2447. The rate at which the first catalyst bed gas 2445 is removed from the first reactor 2440 through the first reactor orifice 2447 is controlled by the first exhaust valve 2470.

The pressure of excess first catalyst bed hydrogen and light hydrocarbon gas 2445 is monitored by a first pressure controller 2450 located above the first catalyst bed 2460. If the pressure of the first catalyst bed gas 2445 is higher than the desired gas pressure, the first pressure controller 2450 tells the first hydrogen valve 2430 to reduce the amount of hydrogen flowing into the first mixer 2420. Will send a signal. When the pressure of the first catalyst bed gas 2445 is lower than the desired gas pressure, the first pressure controller 2450 tells the first hydrogen valve 2430 to increase the amount of hydrogen flowing into the first mixer 2420. Will send a signal.

The first catalyst bed product 2446 flows out of the first reactor 2440 through the first reactor outlet 2444. First catalyst bed product 2446 flows into third mixer 2480 through third mixer inlet 2484, where it enters second mixer 2480 through fourth mixer inlet 2488 and hydrogen 2492. Mixed with The amount of hydrogen 2492 is controlled by the second hydrogen valve 2490. The first catalyst bed product / hydrogen 2482 flows out of the second mixer 2480 through the second mixer outlet 2486 and flows into the second reactor 2500 through the second reactor inlet 2502. Within the second reactor 2500, the first catalyst bed product / hydrogen 2258 reacts while flowing through the second catalyst bed 2520. As the first catalyst bed product / hydrogen 2482 reacts, the second catalyst bed hydrogen gas and light hydrocarbon gas 2505 may be released from the solution and accumulate at the top of the second reactor 2500. The second catalyst bed gas 2505 is removed from the second reactor 2500 through the second reactor orifice 2507. The rate at which the second catalyst bed gas 2505 is removed from the second reactor 2500 through the second reactor orifice 2507 is controlled by the second exhaust valve 2530.

The pressure of excess second catalyst bed hydrogen and light hydrocarbon gas 2505 is monitored by a second pressure controller 2510 located above the second catalyst bed 2520. If the pressure of the second catalyst bed gas 2505 is higher than the desired gas pressure, the second pressure controller 2510 tells the second hydrogen valve 2490 to reduce the amount of hydrogen flowing into the second mixer 2480. Will send a signal. If the pressure of the second catalyst bed gas 2505 is lower than the desired gas pressure, the second pressure controller 2510 tells the second hydrogen valve 2490 to increase the amount of hydrogen flowing into the second mixer 2480. Will send a signal.

Reacted product 2506 exits second reactor 2500 through second reactor outlet 2504. Reacted product 2506 flows through second orifice 2542 into second partition 2540, where it is two flows, second partition 2540 through fifth orifice 2544. Split and reacted product 2252 and recycled and reacted product 2556 exiting second partition 2540 through sixth orifice 2546 are discharged from. Recycled and reacted product 2556 is pumped through recycle pump 2560 and then mixed with fresh feed 2402 in first partition 2410.

FIG. 14 is a diagram of a downflow multilayer reactor system, represented generally by the number 2800, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feed 2802 flows through first orifice 2804 into first partition 2810. Recycled and reacted product 2956 flows into second orifice 2806 and mixed recycled and reacted product and feed 2812 flows out of first partition 2828 through third orifice 2808 do. The mixed recycled and reacted product and feed 2812 then enters the first mixer 2820 via the first mixer inlet 2824, where it is through the second mixer orifice 2828 and the first mixer 2820. Mixed with hydrogen (2832). The amount of hydrogen 2832 is controlled by the first hydrogen valve 2830. Recycled and reacted product / feed / hydrogen 2822 flows out of first mixer 2820 via first mixer outlet 2826 and flows into reactor 2840 through reactor inlet 2842. Within reactor 2840, recycled and reacted product / feed / hydrogen 2822 reacts here while flowing through first catalyst bed 2860. As the recycled and reacted product / feed / hydrogen 2822 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 2845 may be released from solution and accumulate at the top of reactor 2840. First catalyst bed gas 2845 is removed from reactor 2840 via first reactor orifice 2847. The rate at which the first catalyst bed gas 2845 is removed from the reactor 2840 via the first reactor orifice 2847 is controlled by the first exhaust valve 2870.

The height of the liquid recycled and reacted product / feed / hydrogen 2822 is monitored in a first height controller 2850 located above the first catalyst bed 2860. If the height of the liquid recycled and reacted product / feed / hydrogen 2822 is higher than the desired liquid height, first height controller 2850 enters first hydrogen valve 2830 into first mixer 2820. It will send a signal to increase the amount of hydrogen. If the height of the liquid recycled and reacted product / feed / hydrogen 2822 is lower than the desired liquid height, then the first height controller 2850 may pass the first hydrogen valve 2830 to the mixer 2820. It will send a signal to reduce the amount.

First catalyst bed product 2846 flows into third mixer 2880 through third mixer inlet 2884, where it enters second mixer 2880 through fourth mixer inlet 2888 and hydrogen 2892. Mixed with The amount of hydrogen 2892 is controlled by the second hydrogen valve 2890. The first catalyst bed product / hydrogen 2882 flows out of the second mixer 2880 through the second mixer outlet 2864 and flows through the second catalyst bed 2920, where it reacts. As the first catalyst layer product / hydrogen 2902 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 2905 may be released from the solution and accumulate at the top of the second catalyst layer 2920. The second catalyst bed gas 2905 is removed through the second reactor orifice 2907. The rate at which the second catalyst bed gas 2905 is removed through the second reactor orifice 2907 is controlled by the second exhaust valve 2930.

The height of the liquid first catalyst bed product / hydrogen 2882 is monitored by a second height controller 2910 located above the second catalyst bed 2920. If the height of the liquid first catalyst bed product / hydrogen 2882 is higher than the desired liquid height, then the second height controller 2910 tells the second hydrogen valve 2890 the amount of hydrogen entering the second mixer 2880. Will signal to increase. If the height of the liquid first catalyst bed product / hydrogen 2902 is lower than the desired liquid height, the second height controller 2910 may inform the second hydrogen valve 2890 of the amount of hydrogen entering the second mixer 2880. Will signal to increase.

Reacted product 2906 exits reactor 2840 through reactor outlet 2844. The reacted product 2846 flows through the fourth orifice 2942 into the second partitioned area 2940, where it is two flows, through the fifth orifice 2944, the second partitioned area 2940. Split and reacted product (2952) exiting from and recycled and reacted product (2956) exiting from the second partitioned area 2940 through the sixth orifice (2946). Recycled and reacted product 2956 is pumped through recycle pump 2960 and then mixed with fresh feed 2802 in first partition 2810.

FIG. 15 is a diagram of a downflow multilayer reactor system, represented generally by the number 3000, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feedstock 3002 flows through first orifice 3004 into first partition 3010. The recycled and reacted product 3156 flows into the second orifice 3006 and the mixed recycled and reacted product and feed 3012 flows out of the first partition 3010 through the third orifice 3008 do. The mixed recycled and reacted product and feed 3012 then enters the first mixer 3020 via the first mixer inlet 3024, where it is through the second mixer inlet 3028 and the first mixer 3020. Mixed with hydrogen 3032 entered. The amount of hydrogen 3032 is controlled by the first hydrogen valve 3030. Recycled and reacted product / feed / hydrogen 3022 flows out of the first mixer 3020 through the first mixer outlet 3026 and flows into the reactor 3040 through the reactor inlet 3042. Within the reactor 3040, the recycled and reacted product / feed / hydrogen 3022 reacts as it flows through the first catalyst bed 3060. As the recycled and reacted product / feed / hydrogen 3022 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 3045 may be released from the solution and accumulate at the top of the reactor 3040. The first catalyst bed gas 3045 is removed from the reactor 3040 through the first reactor orifice 3047. The rate at which the first catalyst bed gas 3045 is removed from the reactor 3040 through the first orifice 3047 is controlled by the first exhaust valve 3070.

The pressure of excess first catalyst bed hydrogen and light hydrocarbon gas 3045 is monitored by a first pressure controller 3050 located above the first catalyst bed 3060. If the pressure of the first catalyst bed gas 3045 is higher than the desired gas pressure then the first pressure controller 3050 will cause the first hydrogen valve 3030 to reduce the amount of hydrogen entering the first mixer 3020 Will send a signal. When the pressure of the first catalyst bed gas 3045 is lower than the desired gas pressure, the first pressure controller 3050 tells the first hydrogen valve 3030 to increase the amount of hydrogen flowing into the first mixer 3020. Will send a signal.

The first catalyst bed product 3046 flows through the third mixer inlet 3084 into the second mixer 3080, where it enters the second mixer 3080 through the fourth mixer inlet 3088. Mixed with The amount of hydrogen 3092 is controlled by the second hydrogen valve 3090. The first catalyst bed product / hydrogen 3082 flows out of the second mixer 3080 through the second mixer outlet 3086 and flows through the second catalyst bed 3120 where it reacts. As the first catalyst layer product / hydrogen 3082 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 3105 may be released from the solution and accumulate at the top of the second catalyst layer 3120. The second catalyst bed gas 3105 is removed through the second reactor orifice 3107. The rate at which the second catalyst bed gas 3105 is removed through the second reactor orifice 3107 is controlled by the second exhaust valve 3120.

The excess second catalyst bed hydrogen and light hydrocarbon gas 3105 pressure is monitored in a second pressure controller 3110 located above the second catalyst bed 3120. If the pressure of the second catalyst bed gas 3105 is higher than the desired gas pressure, the second pressure controller 3110 tells the second hydrogen valve 3090 to reduce the amount of hydrogen flowing into the second mixer 3080. Will send a signal. If the pressure of the second catalyst bed gas 3105 is lower than the desired gas pressure, the second pressure controller 3110 tells the second hydrogen valve 3090 to increase the amount of hydrogen flowing into the second mixer 3080. Will send a signal.

Reacted product 3106 exits reactor 3040 through reactor outlet 3004. Reacted product 3106 flows through second orifice 3142 into second partition 3140, where it is two flows, second partition 3140 through fifth orifice 3144. Split and reacted product 3152 exiting from and through recycled and reacted product 3156 exiting second partition 3140 through sixth orifice 3146. The recycled and reacted product 3156 is pumped through the recycle pump 3160 and then mixed with fresh feed 3002 in the first partition 3010.

FIG. 16 is a diagram of an upflow multilayer reactor system, represented generally by the number 3200, wherein the amount of liquid in the reactor is controlled by the height of the liquid in the reactor. Fresh feed 3202 flows through first orifice 3204 into first partition 3210. Recycled and reacted product 3356 flows into second orifice 3206, and mixed recycled and reacted product and feed 3212 flow out of first partition 3210 through third orifice 3208. do. The mixed recycled and reacted product and feed 3212 then enter first mixer 3220 via first mixer inlet 3224, where it is first mixer 3220 through second mixer inlet 3228. Mixed with hydrogen (3232). The amount of hydrogen 3322 is controlled by the first hydrogen valve 3230. Recycled and reacted product / feed / hydrogen 3222 exits from first mixer 3220 via first mixer outlet 3326 and flows into reactor 3240 through reactor inlet 3422. Within the reactor 3240, the recycled and reacted product / feed / hydrogen 3222 reacts while flowing through the first catalyst bed 3260. As the recycled and reacted product / feed / hydrogen 3322 reacts, the first catalyst bed hydrogen gas and light hydrocarbon gas 3245 may be released from solution and accumulate at the top of reactor 3240. First catalyst bed gas 3245 is removed from reactor 3240 through first reactor orifice 3247. The rate at which the first catalyst bed gas 3245 is removed from the reactor 3240 through the first reactor orifice 3247 is controlled by the first exhaust valve 3270.

The height of the liquid recycled and reacted product / feed / hydrogen 3222 is monitored by a first height controller 3250 located above the first catalyst bed 3260. If the height of the liquid recycled and reacted product / feed / hydrogen 3222 is higher than the desired liquid height, first height controller 3250 enters first hydrogen valve 3230 into first mixer 3220. It will send a signal to increase the amount of hydrogen. If the height of the liquid recycled and reacted product / feed / hydrogen 3222 is lower than the desired liquid height, first height controller 3250 enters first hydrogen valve 3230 into first mixer 3220. It will send a signal to reduce the amount of hydrogen.

The first catalyst bed product 3246 flows through the third mixer inlet 3284 into the second mixer 3280, where it enters the second mixer 3280 through the fourth mixer inlet 3288 Mixed with The amount of hydrogen 3292 is controlled by the second hydrogen valve 3290. The first catalyst bed product / hydrogen 3328 flows out of the second mixer 3280 through the second mixer outlet 3386 and reacts there while flowing through the second catalyst bed 3120. As the first catalyst layer product / hydrogen 3328 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 3305 may be released from the solution and accumulate at the top of the second catalyst layer 3320. The second catalyst bed gas 3305 is removed through the second reactor orifice 3307. The rate at which the second catalyst bed gas 3305 is removed through the second reactor orifice 3307 is controlled by the second exhaust valve 3330.

The height of the first catalyst bed product / hydrogen 3328 is monitored by a second height controller 3310 located above the second catalyst bed 3320. If the height of the first catalyst bed product / hydrogen 3328 is higher than the desired liquid height, the second height controller 3310 increases the amount of hydrogen entering the second mixer 3280 to the second hydrogen valve 3290. Will send a signal. When the height of the first catalyst bed product / hydrogen 3328 is lower than the desired liquid height, the second height controller 3310 increases the amount of hydrogen flowing into the second mixer 3280 to the second hydrogen valve 3290. Will send a signal.

Reacted product 3306 exits reactor 3240 through reactor outlet 3244. Reacted product 3246 flows through second orifice 3332 into second partition 3340, where it is two flows, second split zone 3340 through fifth orifice 3344. And the recycled and reacted product 3356 exiting from the second partition 3340 via the split and reacted product 3332 and the sixth orifice 3346 emanating from it. The recycled and reacted product 3356 is pumped through recycle pump 3360 and then mixed with fresh feed 3202 in first partition 3210.

FIG. 17 is a diagram of an upflow multilayer reactor system, represented generally by the numeral 3400, wherein the amount of liquid in the reactor is controlled by the pressure of the gas in the reactor. Fresh feed 3402 flows through first orifice 3404 into first partition 3410. Recycled and reacted product 3556 flows into second orifice 3406, and mixed recycled and reacted product and feed 3412 flow out of first partition 3410 through third orifice 3408. do. The mixed recycled and reacted product and feed 3412 then enters the first mixer 3420 through the first mixer inlet 3424, where it is through the second mixer inlet 3428 and the first mixer 3420. Mixed with hydrogen 3432. The amount of hydrogen 3432 is controlled by the first hydrogen valve 3430. Recycled and reacted product / feed / hydrogen 3342 exits the first mixer 3420 through the first mixer outlet 3426 and flows into the reactor 3440 through the reactor inlet 3442. Within the reactor 3440, the recycled and reacted product / feed / hydrogen 3342 reacts while flowing through the first catalyst bed 3460. As the recycled and reacted product / feed / hydrogen 3422 reacts, the first catalyst bed hydrogen gas and the light hydrocarbon gas 3445 may exit the solution and accumulate in the upper end of the reactor 3440. First catalyst bed gas 3445 is removed from reactor 3440 through first reactor orifice 3447. The rate at which the first catalyst bed gas 3445 is removed from the reactor 3440 via the orifice 3447 is controlled by the first exhaust valve 3470.

The pressure of excess first catalyst bed hydrogen and light hydrocarbon gas 3445 is monitored by a first pressure controller 3450 located above the first catalyst bed 3460. If the pressure of the first catalyst bed gas 3445 is higher than the desired gas pressure then the first pressure controller 3450 will cause the first hydrogen valve 3430 to reduce the amount of hydrogen entering the first mixer 3420 Will send a signal. If the pressure of the first catalyst bed gas 3445 is lower than the desired gas pressure then the first pressure controller 3450 will cause the first hydrogen valve 3430 to increase the amount of hydrogen entering the first mixer 3420 Will send a signal.

The first catalyst bed product 3446 flows through the third mixer inlet 3484 into the second mixer 3480, where it enters the second mixer 3480 through the fourth mixer inlet 3488. Mixed with The amount of hydrogen 3492 is controlled by the second hydrogen valve 3490. The first catalyst bed product / hydrogen 3348 flows out of the second mixer 3480 through the second mixer outlet 3386 and flows through the second catalyst bed 3520 where it reacts. As the first catalyst layer product / hydrogen 3348 reacts, the second catalyst layer hydrogen gas and light hydrocarbon gas 3505 may be released from the solution and accumulate at the top of the second catalyst layer 3520. The second catalyst bed gas 3505 is removed through the second reactor orifice 3507. The rate at which the second catalyst bed gas 3505 is removed through the second reactor orifice 3507 is controlled by the second exhaust valve 3530.

The pressure of the excess second catalyst bed hydrogen and light hydrocarbon gas 3505 is monitored by a second pressure controller 3510 located above the second catalyst bed 3520. If the pressure of the second catalyst bed gas 3505 is higher than the desired gas pressure, the second pressure controller 3510 may cause the second hydrogen valve 3490 to reduce the amount of hydrogen entering the second mixer 3480. Will send a signal. If the pressure of the second catalyst bed gas 3505 is lower than the desired gas pressure, the second pressure controller 3510 tells the second hydrogen valve 3490 to increase the amount of hydrogen introduced into the second mixer 3480. Will send a signal.

Reacted product 3506 exits reactor 3440 through reactor outlet 3444. Reacted product 3446 flows through second orifice 3542 into second partition 3540, where it is two flows, second split zone 3540, through fifth orifice 3344. The split and reacted product 3652 and the recycled and reacted product 3556 are discharged from the second partition 3540 through the sixth orifice 3546. The recycled and reacted product 3556 is pumped through the recycle pump 3560 and then mixed with fresh feed 3402 in the first partition 3410.

FIG. 18 is a diagram of a single bed reactor with a height controller for use in a downflow continuous liquid phase hydroprocessing process, indicated generally by the number 4000. The reactor 4000 consists of a vessel 4010 having an inlet orifice 4042 and an outlet orifice 4044. The interior of the reactor 4000 has two upper zones 4020 containing gas 4025, and a much larger lower zone 4030 containing liquid 4035 and a catalyst layer 4060 consisting of catalyst particles 4062. It is divided into bands.

Height controller 4050 is used to maintain the amount of liquid 4035 in lower zone 4030 at a height higher than catalyst bed 4060. Exhaust port 4047 discharges gas 4025 from upper zone 4020 at a predetermined constant rate. The exhaust port 4047 is controlled by the exhaust valve 4070.

FIG. 19 is a diagram of a multilayer reactor with a pressure controller for use in an upflow continuous liquid phase hydroprocessing process, indicated generally by the numeral 4200. Reactor 4200 consists of vessel 4210 with inlet orifice 4242 and outlet orifice 4244. The interior of the reactor consists of a first catalyst layer 4260 consisting of catalyst particles 4426, followed by a mixer 4280, and then a second catalyst layer 4320 consisting of catalyst particles 4322.

The portion of reactor 4200 located between reactor inlet 4242 and mixer 4280 includes an upper zone 4220 containing gas 4225, and a much larger bottom containing catalyst layer 4260 and liquid 4235. It is divided into two bands of the band 4230.

Pressure controller 4250 is used to maintain the pressure of gas 4225 in upper zone 4220 at a predetermined pressure. Exhaust port 4247 discharges gas 4225 from upper zone 4220 at a predetermined constant rate. The exhaust port 4247 is controlled by the exhaust valve 4270.

Mixer 4280 has a first inlet 4288 for introducing liquid 4235 into mixer 4280, a second inlet 4288 for introducing hydrogen into mixer 4280, and an outlet through second catalyst layer 4320. (4286).

The portion of reactor 4200 located between mixer 4280 and reactor outlet 4244 has an upper zone 4350 containing gas 4355, and a much larger lower portion containing catalyst layer 4320 and liquid 4355. It is divided into two bands of the band 4360.

Pressure controller 4310 is used to maintain the pressure of gas 4355 in upper zone 4350 at a predetermined pressure. Exhaust port 4307 discharges gas 4355 from upper zone 4350 at a predetermined constant rate. The exhaust port 4307 is controlled by the exhaust valve 4330.

According to the invention, the deasphalted solvent comprises propane, butane and / or pentane. Other feed diluents include light hydrocarbons, light distillates, naphtha, diesel, VGO, prehydrogenated stocks, recycled hydrocrackates, isomerates, recycled demetallisates, and the like.

Example

Example  One

A feed selected from the group consisting of petroleum fractions, distillates, residual oils, waxes, lubricating oils, fuels other than DAO, or diesel fuel is hydrogenated at 620 K to remove sulfur and nitrogen. To produce a product that meets specifications, about 200 SCF (5.66 m 3) of hydrogen per barrel of diesel fuel must react. Diluents are selected from the group consisting of propane, butane, pentane, light hydrocarbons, light distillates, naphtha, diesel, VGO, prehydrogenated stocks or combinations thereof. A tubular reactor operating at an outlet temperature of 620 K, with a recycle to feed ratio of 1/1 or 2/1 at 65 or 95 bar, is sufficient to carry out the desired reaction.

Example  2

A feed selected from the group consisting of petroleum fractions, distillates, bottom oils, oils, waxes, lubricants, DAO, deasphalted oils and the like is hydrogenated at 620 K to remove sulfur and nitrogen and to saturate the aromatics. About 1000 SCF (28.32 m 3) of hydrogen must be reacted per barrel of deasphalted oil to produce a product that meets specifications. Diluents are selected from the group consisting of propane, butane, pentane, light hydrocarbons, light distillates, naphtha, diesel, VGO, prehydrogenated stocks or combinations thereof. With a recycle ratio of 2.5 / 1 at 80 bar, a tubular reactor operating at an outlet temperature of 620 K is sufficient to provide all the hydrogen required and to allow a temperature rise of less than 20 K throughout the reactor.

Example  3

 Continuous liquid phase hydrotreatment methods and apparatus as described and specified herein.

Example  4

A process for hydrotreating, wherein the hydrogen solubility comprises mixing and / or flashing hydrogen and the treated oil in the presence of a solvent or diluent having a higher relative to the oil feed.

Example  5

Example 4, wherein the solvent or diluent is selected from the group consisting of heavy naphtha, propane, butane, pentane, light hydrocarbons, light distillates, naphtha, diesel, VGO, prehydrogenated stocks, or combinations thereof.

Example  6

Example 5 wherein the feed is selected from the group consisting of oils, petroleum fractions, distillates, residual oils, diesel fuels, deasphalted oils, waxes, lubricants and the like.

Example  7

Blending the feed with the diluent, saturating the diluent / feed mixture with hydrogen at the front of the reactor, and feeding the reactor to saturate or remove sulfur, nitrogen, oxygen metal or other contaminants or to reduce molecular weight or decomposition A method of continuous liquid phase hydrogenation comprising reacting a water / diluent / hydrogen mixture with a catalyst.

Example  8

Example 7 wherein the reactor is maintained at a pressure of 500 to 5000 psi (3447 to 34,473 kPa), preferably 1000 to 3000 psi (6895 to 20,684 kPa).

Example  9

Example 8, further comprising the step of operating the reactor in supercritical solution conditions such that there is no solubility limitation.

Example  10

Example 9, further comprising removing heat from the reactor effluent, separating the diluent from the reacted feed, and recycling the diluent to a point upstream of the reactor.

Example  11

A petroleum product which is prepared by one of the embodiments described above, hydroprocessed, hydroreformed, post-hydrotreated, hydrorefined, hydrocracked, and the like.

Example  12

The reaction vessel used in the improved hydrocracking process of the present invention has an approximate reactor volume of 40 ft ³ (1.13 m ³ ), is configured to withstand pressures of about 3000 psi (20,684 kPa) or less, and is 2 inches ( 5.08 cm) diameter in a relatively small tube.

Example  13

In the solvent deasphalting process, eight volumes of n-butane are contacted with one volume of the bottom of the vacuum tower. After removing the pitch but before recovering the solvent from the deasphalted oil (DAO), the solvent / DAO mixture is pumped to about 1000 to 1500 psi (6895 to 10,342 kPa) and approximately 900 SCF (25.4 m 3) per barrel of DAO Mix with H ₂ . The solvent / DAO / hydrogen mixture is heated to about 590-620 K and contacted with a catalyst to remove sulfur and nitrogen and to saturate the aromatics. After hydroreforming, butane is recovered from the hydrogenated DAO by reducing the pressure to about 600 psi (4137 kPa).

Example  14

A multistage reactor having a structure according to the invention, in which two or more reactors having the same or different temperatures, pressures, catalysts and the like are arranged in series, and / or a multilayer reactor in which two or more catalyst beds are arranged in a single reactor according to the invention. One or more of the above embodiments.

Example  15

In addition to Example 14 above, special products, waxes, lubricants, and the like are prepared using a multistage reactor.

In summary, hydrocracking is the decomposition of carbon-carbon bonds and hydroisomerization is the rearrangement of carbon-carbon bonds. Hydrodemetallization is usually the removal of metal from the bottom of a vacuum tower or from deasphalted oil to avoid catalytic poisoning in cat crackers and hydrocrackers.

Example  16

Hydrocracking: A volume of vacuum gas oil is mixed with 1000 SCF (6895 kPa) H ₂ per barrel of gas oil feed, blended with 2 volumes of recycled hydrocracked product (diluent), 750 ° F. (399 ° C.) and Pass the hydrocracking catalyst at 2000 psi (13,789 kPa). The hydrocracked product contained 20% naphtha, 40% diesel and 40% residual oil.

Example  17

Hydroisomerization: A volume of feed containing 80% paraffin wax is mixed with 200 SCF (5.66 m 3) H ₂ per barrel of feed, blended with 1 volume of isomerized as diluent, and 550 ° F. (287.8) ° C) and 2000 psi (13,789 kPa) through an isomerization catalyst. Isomerates have a pour point of 30 ° F. (−1 ° C.) and VI of 140.

Example  18

Hydrodemetallization: A volume of feed containing a total of 80 ppm of metal is blended with 150 SCF (4.25 kPa) H ₂ per barrel, mixed with 1 volume of recycled demetallization, and 450 ° F. (232). C) and 1000 psi (6895 kPa). The product contained a total of 3 ppm metal.

In general, Fischer-Tropsch refers to the production of paraffin from carbon monoxide and hydrogen (CO and H ₂ or synthetic gas). Syngas contains CO ₂ , CO, H ₂ and is produced from various sources, mainly coal or natural gas. The synthesis gas is then reacted on a specific catalyst to produce a specific product.

Fischer-Tropsch synthesis is the production of hydrocarbons, paraffin, almost alone from CO and H ₂ on supported metal catalysts. The classic Fischer-Tropsch catalyst is iron, but other metal catalysts are also used.

Syngas can be used and used to produce other chemicals, primarily alcohols, although not Fischer-Tropsch reactions. The technique of the present invention can be used in any catalytic process where one or more components in the reaction on the catalyst surface must be transferred from the gas phase to the liquid phase.

Example  19

After operating the first stage at conditions sufficient to remove sulfur, nitrogen, oxygen, etc. [620 K, 100 psi (689 kPa)], contaminants H ₂ S, NH ₃ and water are removed and the second stage reactor is A two-stage hydrotreatment process operated under conditions sufficient for saturation of an aromatic.

Example  20

In addition to hydrogen, carbon monoxide (CO) is mixed with hydrogen and the mixture is contacted with a Fischer-Tropsch catalyst for the synthesis of hydrocarbons.

Example  21

As mentioned in one or more embodiments above, the amount of liquid feed / diluent / hydrogen mixture in the reactor is controlled by the height of the liquid feed / diluent / hydrogen mixture and reacted liquid feed / diluent / hydrogen mixture in the reactor. Same process.

The height of the liquid in the reactor is kept higher than the top of the catalyst bed in the reactor and monitored by the height controller. As the height of the liquid in the reactor increases or decreases, the amount of hydrogen added to the feed / diluent mixture is adjusted to lower or raise the height of the liquid in the reactor, respectively.

Example  22

The process as mentioned in the one or more embodiments above, wherein the amount of liquid feed / diluent / hydrogen mixture in the reactor is controlled by the pressure of excess hydrogen gas and light hydrocarbon gas at the top of the reactor.

The pressure of the gas at the top of the reactor is maintained at a particular pressure suitable for the particular application, for the feed and the desired product specifications. As the pressure of the gas at the top of the reactor increases or decreases, the amount of hydrogen added to the feed / diluent mixture is adjusted to increase or decrease the pressure of the gas at the top of the reactor, respectively.

Although only a part of the form of the invention has been specified, it will be apparent to those skilled in the art that the invention is not so limited and that various modifications and adaptations may be made without departing from the scope of the invention. Accordingly, the appended claims are to be interpreted broadly to coincide with the scope of the present invention.

Claims (3)

A control system for a continuous liquid phase hydroprocessing reactor having an upper zone of gas and a much larger lower zone of liquid surrounding the catalyst,
(a) an indicator located on the reactor;
(b) means for sensing the amount of liquid in the reactor;
(c) indicator readings obtained from the sensing means;
(d) means for converting the indicator readings into an indicator signal;
(e) a computer for receiving the indicator signal;
(f) means for transmitting an indicator signal to the computer;
(g) a software program that interprets the indicator signal and makes adjustments based on the indicator signal;
(h) means for converting said adjustment value into an adjustment signal;
(i) means for conveying said adjustment signal;
(j) a hydrogen control valve located upstream from the reactor to regulate the amount of hydrogen entering the reactor feed;
(k) means for interpreting an adjustment signal at said hydrogen control valve; And
(l) means for adjusting the hydrogen control valve based on the analysis means
Control system comprising a. The control system of claim 1, wherein the indicator on the reactor is a liquid height indicator. The control system of claim 1, wherein the indicator on the reactor is a gas pressure indicator.

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